What are conveyor belts used for?

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What are mining conveyor belts and how to choose the best one for your operations?

Is there any specific rubber conveyor belt for the mining operations?

From ore and rock extraction to processing and finally transporting them, the mining industry includes an array of demanding operations. Multiple components keep the conveyor systems running- bearings, winches, fluid couplings, gearboxes, motors, and scrapers work together to move materials from one point to another.

While everything is working in unison, efficient conveying is what matters the most.
Smart buyers must know well about specific conveyor belt types before buying. With advancements in technology, a rubber conveyor belt is getting upgraded every day. But, if you are looking for compact information on a belt and conveyor, here you go:

What Is A Mining Conveyor Belt?

A mining rubber conveyor belt is a moving strip of rubber that is run by pulleys. The key components of a conveyor belt for mining include:

• A Rubber Cover
• Pulleys
• Motors That Power The Belt And Conveyor
• Rollers With Bearings
• Tensioning Systems

Mining rubber conveyor belt has a similar structure to the conveyor belts used in other core industries like construction or manufacturing. However, since mining includes rigorous application and exposure to extreme temperatures, a mining conveyor belt must have a durable cover- heat and fire-resistant.

5 Uses of Rubber Conveyor Belt In The Mining Industry

Ore and Waste Rock Transportation

A Fundamental application of a rubber conveyor belt in mining is the transportation of materials extracted. They move ore, coal, and other valuable minerals from the mines to processing plants or stockpiles. This minimizes the need for manual labor or numerous mining trucks, significantly reducing costs as well.
A mining belt and conveyor can operate in both horizontal and inclined positions, making them adaptable to different mining environments, like underground mines and open-pit operations.
Since the materials mined have sharp edges, here you should choose a conveyor belt that has strong anti-abrasive properties. Otherwise, you may have to frequently replace conveyor belt types made of low-grade rubber.
Explore Duratuf General Purpose Conveyor Belt– available in 3 types for varied levels of abrasion.

Sorting and Processing of Mined Materials

A rubber conveyor belt helps with the sorting and processing of mined materials. They transport crushed rock, coal, and other minerals through various processing stages. Some of the processing stages include: crushing, screening, washing, and sizing. This allows for the quick separation of valuable minerals from waste rock.
Moreover, a belt and conveyor here ensure that the final product meets the required specifications.
Modern conveyor belts can be equipped with sensors and automated systems to identify and remove unwanted materials. But, during the sorting of mined materials, the rubber cover of the conveyor belts can get affected by continuous running.
The friction generated from the pulleys slowly degrades the bottom cover, as well. A Pulley Lagging Sheet can safeguard your rubber conveyor belt here.

Stockpiling and Loading of Mined Materials

The belt and conveyor play a significant role in stockpiling and loading mined materials. They convey processed materials to designated stockpiles for temporary storage. They also move mined materials directly onto trucks, trains, or ships for transportation to processing facilities or consumers.
This seamless movement of mined materials reduces manual handling, reducing dependency on heavy machinery. Additionally, conveyor belts can be designed with specific features, such as a stacker and reclaimer, to manage stockpiles with fine precision.
However, even with the best-quality rubber conveyor belt, you may face long production downtime. Do you know you can easily manage some of the issues? 7 problems in rubber conveyor belts and their solutions!

Conveying Over Long Distances

Did you know the longest single conveyor belt in the world goes to the 51-kilometer (31.6-mile) system located in Western Australia (Guinness Book of World Records)? This belt transports bauxite ore from the Mount Saddleback mine to the Worsley refinery near Collie.
In some mining operations, conveying materials over long distances is essential. This is where overland conveyor systems come into the picture. These massive conveyor belts stretch for kilometers, efficiently moving large quantities of materials across vast distances.
Overland conveyors offer a cost-effective and environment-friendly alternative to traditional mining trucks.
As per our research as a trusted supplier conveyor belt, the right conveyor belt types reduce reliance on road infrastructure, minimize fuel consumption and emissions, and contribute to a more sustainable mining operation.

Elevating Materials to Different Levels

A rubber conveyor belt can be used for more than horizontal transportation. They can also be inclined or even vertical, allowing them to elevate materials to different levels within a mine or processing center. This is important for moving materials between different processing stages or conveying them to stockpiles located at higher elevations.
Inclined conveyor belts are designed to handle the additional challenge of gravitational pull, ensuring safe upward material movement.

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How to Choose a Mining Rubber Conveyor Belt?

Keep in mind these 3 major factors while buying a mining conveyor belt: Abrasion Level, Heat Resistance, and Fire Resistance.

Abrasion Level: Abrasion affects the rubber cover, slowly weakening it. Iron ore, copper, lignite, limestone, and blast furnace slag are highly abrasive. In quarry and mining, a rubber conveyor belt also conveys fine materials like slacked lime. The Duratuf General Purpose Rubber Conveyor Belts have tested anti-abrasive strength and are available in three types.

Name Duratuf MaxGuard Characterization Extreme Abrasion, Superior Resistance to Cutting & Tearing Tensile Strength (MPa) 24 Elongation at Break (%) 450 Abrasion (mm3) 120 Hardness (SHA) 60+/-5 Adhesion Cover to Ply (N/mm) 3 Ply to Ply (N/mm) 4.4 Adhesion Cover to Ply (N/mm) 4 Name Duratuf Guardian Characterization High Abrasion, Superior to Cutting & Tearing Tensile Strength (MPa) 17 Elongation at Break (%) 450 Abrasion (mm3) 200 Hardness (SHA) 60+/-5 Adhesion Cover to Ply (N/mm) 3 Ply to Ply (N/mm) 4.4 Adhesion Cover to Ply (N/mm) 4 Name Duratuf LiteGuard Characterization Resistance to Cutting and Gouging.Flexible at lower temperature. Tensile Strength (MPa) 12 Elongation at Break (%) 400 Abrasion (mm3) 250 Hardness (SHA) 60+/-5 Adhesion Cover to Ply (N/mm) 3 Ply to Ply (N/mm) 4.4 Adhesion Cover to Ply (N/mm) 4

Heat-Resistance: For hot mining materials or byproducts like coke, soda ash, and BF slag, the ply cover of the belt and conveyor must have heat-resistant properties. Presenting Duratuf HeatGuard- a superior choice for heat resistance:

Characterization Heat Resistant_ Working Temperature Range- 100°C – 150°C Tensile Strength (MPa) 15 Elongation at Break (%) 400 Abrasion (mm3) 150 Hardness (SHA) 60+/-5 Adhesion Cover to Ply (N/mm) 3 Ply to Ply ( N/mm) 4.5

Fire-Resistance: A rubber conveyor belt for conveying inflammable mined materials should have extinguishable properties- a unique feature that promises safety.

Characterization Flame Retardant Tensile Strength (MPa) 15 Elongation at Break (%) 350 Abrasion (mm3) 200 Hardness (SHA) 60+/-5 Adhesion Cover to Ply (N/mm) 3 Ply to Ply ( N/mm) 4

Buying the Right Belt and Conveyor, Offers You These Benefits:

• Material Flow Optimization: The right rubber conveyor belt guarantees a smooth and continuous material flow, reducing bottlenecks.
• Reduced Downtime: Properly selected belt and conveyor require less maintenance and experience fewer breakdowns, leading to reduced downtime and increased productivity.
• Energy Efficiency: Conveyor belts designed for specific applications often have features that reduce the consumption of energy, resulting in long-term cost savings.
• Lesser Maintenance Costs: Choosing the right rubber conveyor belt with minimal maintenance requirements can lead to significant cost savings over time.
• Personnel Safety: The appropriate rubber conveyor belt minimizes the risk of accidents, ensuring the safe transport of materials and, in some cases, even personnel.
• Fire Resistance: Conveyor belt types designed with fire-resistant materials enhance workplace safety, especially in industries where the risk of fire is present.
• Wear Resistance: The right conveyor belt, selected based on the type of materials being transported, can resist wear and abrasion, leading to a longer life span and reduced replacement frequency.
• Corrosion Resistance: In corrosive environments, ask your supplier conveyor belt for belts with resistance to harsh substances.
• Gentler Material Handling: A rubber conveyor belt with features like adjustable speed and gentle handling capabilities prevent material degradation. As a result, it maintains the quality of the transported goods, particularly in food-processing industries.

Check out the features of Duratuf Conveyor Belts.
Trusted by + customers in 52 countries in the world, top businesses find our industrial rubber products of unparalleled quality.

The Bottom Line

Top 7 Safety Features Your Conveyor Should Have

Adhering to complex OSHA mining conveyor safety regulations can be an ongoing challenge. There are many moving parts and areas where accidents could occur. However, failure to comply poses serious legal, financial, and reputational risks.

Adding key safety features to your conveyor systems can mitigate hazards and ensure your operations conform to regulatory rules. Read on to learn more about OSHA conveyor safety and compliance.

IMPORTANCE OF CONVEYOR SAFETY IN MINING

Mining conveyors pose inherent safety risks due to multiple moving parts, heavy loads, and continuous operation. Well-implemented safety components and protocols ensure compliance and foster a safe working environment. 

Here are the top seven mining conveyor safety features you should consider:

1. GUARDING

Proper conveyor guarding prevents access to moving parts and hazardous areas. It is an effective measure to protect operators from injuries caused by moving components. The impact of guarding on worker safety is significant, as it directly reduces the risk of accidents and injuries.

OSHA REGULATIONS ON GUARDING

OSHA’s General Industry Standard, specifically 29 CFR .219, underlines the requirements for guarding machinery. This standard directly applies to conveyor systems, mandating guards to protect workers from moving parts, pinch points, and other potential hazards.

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For more information, please visit Ore Conveyor Belt.

2. EMERGENCY SHUT-OFF BUTTONS

Emergency shut-off buttons or pull cords are vital for immediate response in hazardous situations. These controls allow for the quick shutdown of the conveyor, thereby minimizing the risk of accidents and enhancing safety. Quick and unimpeded access to emergency controls is essential for effective emergency response.

OSHA STANDARDS FOR EMERGENCY CONTROLS

According to OSHA’s Conveyor Standard, 29 CFR .261, conveyors must have easily accessible emergency stop devices. This regulation ensures workers can quickly halt conveyor operations in an emergency.

3. START-UP WARNING SYSTEMS

Start-up warning systems allow operators and nearby workers sufficient time to clear the area before the conveyor starts. These systems provide audible or visible signals that enhance safety by alerting workers allowing them to move to safe locations.

OSHA AND START-UP WARNINGS

OSHA guidelines related to conveyor warning systems are an integral part of safety protocols. These guidelines ensure that workers have adequate warning before the conveyor operation commences. This early warning system helps to reduce accident risks significantly.

4. SCHEDULED MAINTENANCE

Performing regular maintenance is vital for spotting safety issues before they worsen. Scheduled inspections and upkeep help find hazards like worn parts, loose components, or faulty equipment. This allows for prompt fixes and helps sustain the conveyor’s safety and integrity.

OSHA’S PERSPECTIVE ON MAINTENANCE

OSHA emphasizes the importance of regular inspections and maintenance of conveyors through its Conveyor Standard, 29 CFR .261. This standard mandates periodic checks to ensure the safe operation of conveyors.

Additionally, following the Lockout/Tagout (LOTO) standard (29 CFR .147) is vital during maintenance to safeguard workers. LOTO prevents unexpected startups that could endanger them.

5. PERSONAL PROTECTIVE EQUIPMENT (PPE)

Wearing proper personal protective equipment (PPE) directly safeguards against many hazards while safeguarding worker health and safety. Required PPE varies by work environment but can include safety glasses, gloves, and hearing protection.

OSHA REGULATIONS ON PPE

The OSHA standard for PPE, 29 CFR .132, mandates employers to assess workplace hazards and provide appropriate personal protective equipment. This standard is crucial for ensuring that employees working with conveyors are adequately protected from potential risks.

6. SENSOR AND ALARMS

Sensors and alarms play a critical role in detecting abnormalities in the conveyor system. They can identify issues like jammed materials, excessive loads, or equipment malfunctions. These warning systems are crucial for preventing shutdowns and accidents, enhancing the overall safety of the conveyor system.

OSHA GUIDELINES FOR TECHNOLOGICAL SAFETY MEASURES

OSHA regulations on using technology for safety in conveyor systems are integral to modern safety protocols. They ensure conveyors have the latest safety technology to detect and respond promptly to potential hazards. Applicable regulations can include:

29 CFR .555 – Conveyors: This regulation covers the safety requirements for various types of conveyors, including using technology to enhance safety.

29 CFR .147 – Control of Hazardous Energy (Lockout/Tagout): While not specific to conveyors, it pertains to machinery safety, which can include safety technology on conveyors.

29 CFR .212 – General Requirements for Guarding of Machinery and Mechanical Power Transmission Apparatus: This regulation addresses guarding and safety measures for machinery, which may involve conveyor systems and their safety technology.

7. PROPER STICKERS AND WARNING LABELS

Stickers and warning labels are essential for conveyor safety. They offer clear, visible instructions and warnings to workers. These labels inform about potential hazards and safety procedures associated with operating or working near conveyors. They serve as reminders for the use of necessary protective gear and guide on safe machinery operation.

OSHA GUIDELINES FOR STICKERS AND WARNING LABELS

Under OSHA’s General Requirements (29 CFR .22), maintaining a safe and orderly workplace is crucial. This includes the use of stickers and warning labels around conveyors. Employees should place these strategically so that they’re easily seen and understood.

WEST RIVER CONVEYORS SAFETY FEATURES 

Our conveyors integrate all the safety components outlined above. If you require any of these mechanisms, you can have us install them directly. Our experienced team fabricates a wide range of customizable guarding options in-house to meet all safety standards.

Our expert fabricators can integrate these safety features into new or existing systems to guarantee compatibility with your West River Conveyors equipment. We comply with OSHA regulations and verify that all necessary protective mechanisms are included on our conveyors.

For instance:

• Guarding complies with the Mechanical Power-Transmission Apparatus standard (29 CFR .219)
• Emergency shut-off buttons adhere to the Conveyor Standard (29 CFR .261)
• Regular inspections and maintenance follow the guidelines of the Conveyor Standard (29 CFR .261) and the Lockout/Tagout standard (29 CFR .147)
• Personal Protective Equipment provided aligns with the OSHA PPE standard (29 CFR .132)

GET EXPERT CONVEYOR SAFETY GUIDANCE  

Implementing the above safety features will help create an efficient, productive, and sustainable working environment. Worker morale will also improve as the company takes the necessary steps to ensure their health and well-being.

At West River Conveyors, we have over 40 years of experience building high-performance and long-lasting mining conveyors for various industries. We can help you navigate through the often-complex maze of conveyor safety regulations and requirements.

We invite you to click below to learn more about our innovative conveyor safety features.

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